Material mesh for screening fines

ABSTRACT

A tubular for reservoir fines control includes a body having an outer surface and an inner surface defining a flow path. A plurality of openings is formed in the body connecting the outer surface and the flow path. A pre-formed member including a material mesh is overlaid onto the outer surface. The material mesh is formed from a material swellable upon exposure to a selected fluid introduced into a wellbore. The material mesh has a selected porosity allowing methane to pass into the flow path while preventing passage of fines.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No. 16/936,620filed Jul. 23, 2020, which is a divisional of U.S. application Ser. No.15/795,708 filed Oct. 27, 2017, now issued as U.S. Pat. No. 10,767,451,which claims the benefit of provisional U.S. Application Ser. No.62/504,676 filed May 11, 2017, the disclosure of each are incorporatedby reference herein in their entirety.

BACKGROUND

Resource extraction techniques typically include forming a borehole andintroducing a system of tubulars to guide a resource, such as oil or gasuphole to be captured and processed. Often time, methane gas may befound in a coalbed. Coalbed methane wells typically include numerousthin layers of clay or interburden between coal seams. Duringextraction, water is pulled from the coal seams allowing gas to escape.However, water flow over reactive clay interburden produces particulatesuch as fines that may enter into a downhole pump. In some cases, thereare so many layers of interburden, zonal isolation is not practical.That is, isolating layers of interburden may block off productiveportion of the coal seams leaving the gas trapped in the formation.

SUMMARY

Disclosed is a tubular for reservoir fines control including a bodyhaving an outer surface and an inner surface defining a flow path. Aplurality of openings is formed in the body connecting the outer surfaceand the flow path. A pre-formed member including a material mesh isoverlaid onto the outer surface. The material mesh is formed from amaterial swellable upon exposure to a selected fluid introduced into awellbore. The material mesh has a selected porosity allowing methane topass into the flow path while preventing passage of fines.

Also disclosed is a method of forming a permeable cover on a perforatedtubular including positioning a pre-formed member having a material meshpermeable to a downhole gas on an outer surface of the perforatedtubular. The material mesh is formed from a material swellable uponexposure to a selected fluid introduced into the wellbore.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings wherein like elements are numbered alikein the several Figures:

FIG. 1 depicts a resource recovery and exploration system including amaterial mesh for providing borehole support and fines screening, inaccordance with an exemplary embodiment;

FIG. 2 depicts a perforated tubular having a first material mesh layerof the material mesh, in accordance with an exemplary embodiment;

FIG. 3 depicts the first material mesh layer of the material mesh, inaccordance with another aspect of an exemplary embodiment;

FIG. 4 depicts the perforated tubular of FIG. 2 having a second materialmesh layer of the material mesh, in accordance with an exemplaryembodiment;

FIG. 5 depicts the perforated tubular of FIG. 3 having a third materialmesh layer of the material mesh, in accordance with an exemplaryembodiment;

FIG. 6 depicts a cross-sectional view of the perforated tubular of FIG.5 ;

FIG. 7 depicts an exemplary cross-sectional profile of a cord formingone or more of the first, second, and third material mesh layers, inaccordance with an exemplary aspect;

FIG. 8 depicts an exemplary cross-sectional profile of a cord formingone or more of the first, second, and third material mesh layers, inaccordance with an exemplary aspect;

FIG. 9 depicts an exemplary cross-sectional profile of a cord formingone or more of the first, second, and third material mesh layers, inaccordance with an exemplary aspect;

FIG. 10 depicts an exemplary cross-sectional profile of a cord formingone or more of the first, second, and third material mesh layers, inaccordance with an exemplary aspect;

FIG. 11 depicts an exemplary cross-sectional profile of a cord formingone or more of the first, second, and third material mesh layers, inaccordance with an exemplary aspect;

FIG. 12 depicts an exemplary cross-sectional profile of a cord formingone or more of the first, second, and third material mesh layers, inaccordance with an exemplary aspect;

FIG. 13 depicts the material mesh after being exposed to a selectedfluid, in accordance with an exemplary aspect;

FIG. 14 depicts a material mesh formed from a continuous cord, inaccordance with an exemplary embodiment;

FIG. 15 depicts a material mesh as a pre-fabricated woven sleeve, inaccordance with an exemplary embodiment;

FIG. 16 depicts the material mesh as a pre-fabricated woven mat, inaccordance with an exemplary embodiment;

FIG. 17 depicts the pre-fabricated woven mat, in accordance with anotheraspect of an exemplary embodiment;

FIG. 18 depicts the material mesh as a pre-fabricated mat formed from aplurality of particles joined by a binder material, in accordance withanother aspect of an exemplary embodiment; and

FIG. 19 depicts the material mesh as a pre-fabricated sleeve formed froma plurality of particles joined by a binder material, in accordance withyet another aspect of an exemplary embodiment.

DETAILED DESCRIPTION

A resource exploration and recovery system, in accordance with anexemplary embodiment, is indicated generally at 2, in FIG. 1 . Resourceexploration and recovery system 2 may include a surface system 4operatively connected to a downhole portion 6. Surface system 4 mayinclude pumps 8 that aid in completion and/or extraction processes.Surface system 4 may also include a fluid storage member 10. Fluidstorage member 10 may contain a gravel pack fluid or slurry (not shown),water, or other fluid which may be utilized in drilling and/orextraction operations.

Downhole portion 6 may include a downhole string 20 formed from aplurality of tubulars, one of which is indicated at 21 that is extendedinto a wellbore 24 formed in formation 26. Wellbore 24 includes anannular wall 28 that may be defined by formation 26. It is to beunderstood that annular wall 28 may also be defined by a casing. One oftubulars 21 may be define a perforated tubular 32 covered by a materialmesh 38.

In accordance with an exemplary aspect depicted in FIG. 2 , perforatedtubular 32 includes a body 44 having an outer surface 46, and an innersurface 48 (FIG. 5 ) that defines a flow path 50 (FIG. 5 ). Perforatedtubular 32 includes a plurality of openings, one of which is shown at54, that extend through outer surface 46 and inner surface 48 such thatwhen deployed downhole, flow path 50 may be fluidically connected withwellbore 24. Perforated tubular 32 includes a first end 56, a second end57, and an intermediate portion 58 defining a longitudinal axis 59extending therebetween.

In accordance with an aspect of an exemplary embodiment, material mesh38 may include a first material mesh layer 60 applied to outer surface46. First material mesh layer 60 may include a plurality of discreteelements or cords 64 that extend axially along longitudinal axis 59 ofperforated tubular 32. It should however be understood that cords 64 mayextend at an angle relative to longitudinal axis 59 or may wrap aroundouter surface 46 as shown in FIG. 3 . Cords 64 may be formed from afirst material 65 that is swellable upon being exposed to a selectedfluid. In accordance with an exemplary embodiment, the selected fluidmay be a downhole fluid such as oil, water, or combinations thereof. Inaccordance with another exemplary aspect, the selected fluid may be afluid introduced from surface system 4.

In further accordance with an exemplary aspect, material mesh 38 mayinclude a second material mesh layer 67 such as shown in FIG. 4 . Secondmaterial mesh layer 67 may be formed from a cord member 69 formed from asecond material 71. Second material 71 is swellable upon being exposedto a selected fluid. Further, second material 71 may be similar to firstmaterial 65 or may be distinct therefrom. For example, first material 65may be swellable upon being exposed to water and second material 71 maybe swellable upon being exposed to oil or vice versa. In accordance withanother exemplary aspect, the selected fluid may be a fluid introducedfrom surface system 4. Second material mesh layer 67 may be overlaidonto first material mesh layer 60 in a variety of patterns. As shown inFIG. 3 , second material mesh layer 67 may be spirally wrapped aboutfirst material mesh layer 60 with a selected spacing between adjacentwraps (not separately labeled).

In still further accordance with an exemplary aspect, material mesh 38may include a third material mesh layer 80 as shown in FIGS. 5 and 6 .Third material mesh layer 80 may be formed from a cord element 82 formedfrom a third material 84. Third material 84 is swellable upon beingexposed to a selected fluid. Further, third material 84 may be similarto first material 65 and second material 71 or may be distincttherefrom. For example, third material 84 may be swellable upon beingexposed to water and/or oil.

In accordance with another exemplary aspect, third material 84 may beswellable upon being exposed to a selected fluid that is introduced fromsurface system 4. Third material mesh layer 80 may be overlaid ontosecond material mesh layer 67 in a variety of patterns. As shown in FIG.5 , third material mesh layer 80 may be spirally wrapped about secondmaterial mesh layer 67 with a selected spacing between adjacent wraps(not separately labeled). Further, a wrap angle (not separately labeled)of third material mesh layer 80 may be opposite to a wrap angle (alsonot separately labeled) for second material mesh layer 67. As shown inFIG. 6 , material mesh 38 may take the form of a number of layersoverlaid onto each other.

It should be appreciated that each of cord 64, cord member 69, and cordelement 82 may include a selected cross-section shape. Thecross-sectional shape may be similar or may vary depending upon desiredscreening requirements. For example, one or more of cord 64, cord member69, and cord element 82 may include a generally circular cross-sectionsuch as shown at 89 in FIG. 7 , a generally rectangular cross-section 92such as shown in FIG. 8 , a generally triangular cross-section 94 suchas shown in FIG. 9 , a generally cross-shaped cross-section 96 such asshown in FIG. 10 , a generally t-shaped cross-section 98 such as shownin FIG. 11 , and/or a generally multi-segmented cross-section 100 suchas shown in FIG. 12 .

In accordance with an exemplary embodiment, after a selected timeperiod, which can vary, upon being exposed to the selected fluid,material mesh 38 will expand so as to define a lager outer diameter thatabuts annular wall 28 of wellbore 24 and establish a desiredpermeability or porosity to screen out fines that may be present inwellbore fluid passing into perforated tubular 32 via openings 54 suchas shown in FIG. 13 .

Reference will now follow to FIG. 14 , wherein like reference numeralrepresent corresponding parts in the respective views, in describing amaterial mesh 105 in accordance with another exemplary aspect. Materialmesh 105 may include a continuous cord 107 formed from a material 109.Continuous cord 107 may be applied in a single layer or in multiplelayers. Continuous cord 107 may include a constant cross-sectionaldimension or a cross-sectional dimension that varies. Continuous cord107 may be applied to perforated tubular 32 at surface system 4 or at anoff-site location.

Further, continuous cord 107 may be extruded at surface system 4 suchthat diameters, shapes and materials may vary according to downholeconditions. In this manner, operators may adjust to downhole conditionson the fly without delays associated with fabricating, transporting, andinstalling preformed mesh. Further, material selection may vary suchthat a portion of material mesh 105 is swellable upon being exposed to afirst fluid and other portions of material mesh 105 are swellable uponbeing exposed to a second fluid that is distinct from the first fluid.

Reference will now follow to FIG. 15 , wherein like reference numeralrepresent corresponding parts in the respective views, in describing amaterial mesh 112 in accordance with another aspect of an exemplaryembodiment. Material mesh 112 may be pre-formed from a material weave orinterlaced cord 114 into a material sleeve 116. Material sleeve 116 mayhave a continuous outer surface (not separately labeled) as shown inFIG. 15 or may take the form of a pre-fabricated woven mat 119 having adiscontinuity, such as shown at 120 in FIG. 16 and FIG. 17 .Discontinuity 120 may define a first end 121 and a second end 122. Firstend 121 may be bonded to second end 122 with an adhesive 125 or, asshown in FIG. 16 , woven mat 119 may be secured to perforated tubular 32with one or more clamps 127, 128. It is to be understood that materialmesh 112 may be formed from a plurality of discrete particles such asshown at 140 in FIG. 18 joined by a binder material (not separatelylabeled) to form a mat 142. Alternatively, particles 140 may be formedinto a sleeve 146 such as shown in FIG. 19 . The discrete particles areswellable upon being exposed to one or more selected fluids.

At this point, it should be understood that exemplary embodimentsdescribe a material mesh that may take the form of one or more layers ofcord applied to an outer surface of a tubular, or a woven mesh. Thematerial mesh may be formed from one or more materials that areswellable when exposed to a selected fluid to establish a selectedporosity or permeability. Upon swelling, material mesh provides supportto internal surfaces of a well bore to enhance fluid production by, forexample, providing reservoir fines control. At the same time, materialmesh defines a fluid permeable cover which screens out fines that may bepresent in the fluid, such as a downhole gas, passing uphole.

The teachings of the present disclosure may be used in a variety of welloperations. These operations may involve using one or more treatmentagents to treat a formation, the fluids resident in a formation, awellbore, and/or equipment in the wellbore, such as production tubing.The treatment agents may be in the form of liquids, gases, solids,semi-solids, and mixtures thereof. Illustrative treatment agentsinclude, but are not limited to, fracturing fluids, acids, steam, water,brine, anti-corrosion agents, cement, permeability modifiers, drillingmuds, emulsifiers, demulsifiers, tracers, flow improvers etc.

Set forth below are some embodiments of the foregoing disclosure:

Embodiment 1. A tubular for reservoir fines control comprising a bodyincluding an outer surface and an inner surface defining a flow path, aplurality of openings is formed in the body connecting the outer surfaceand the flow path, and a pre-formed member including a material meshoverlaid onto the outer surface, the material mesh being formed from amaterial swellable upon exposure to a selected fluid introduced into awellbore, the material mesh having a selected porosity allowing methaneto pass into the flow path while preventing passage of fines.

Embodiment 2. The tubular according to any prior embodiment, wherein theselected fluid is introduced from a surface system into the wellbore.

Embodiment 3: The tubular according to any prior embodiment, wherein aportion of the material mesh extends at an angle relative to alongitudinal axis of the body.

Embodiment 4: The tubular according to any prior embodiment, wherein thepre-formed member comprises a pre-formed sleeve.

Embodiment 5: The tubular according to any prior embodiment, wherein thepre-formed member comprises a weave.

Embodiment 6: The tubular according to any prior embodiment, wherein thepre-formed member comprises a mat having a first end and a second end.

Embodiment 7: The tubular according to any prior embodiment, wherein themat is clamped to the outer surface.

Embodiment 8: The tubular according to any prior embodiment, wherein themat is secured about the outer surface with the first end being bondedto the second end.

Embodiment 9: The tubular according to any prior embodiment, wherein thepre-formed member comprises a continuous cord.

Embodiment 10: The tubular according to any prior embodiment, whereinthe continuous cord includes a first portion having a first dimensionand a second portion having a second dimension that is distinct from thefirst dimension.

Embodiment 11: The tubular according to any prior embodiment, whereinthe pre-formed member is formed from a plurality of discrete particlessuspended in a binder material.

Embodiment 12: A method of forming a permeable cover on a perforatedtubular comprising positioning a pre-formed member including a materialmesh permeable to a downhole gas on an outer surface of the perforatedtubular, the material mesh being formed from a material swellable uponexposure to a selected fluid introduced into the wellbore.

Embodiment 13: The method according to any prior embodiment, furthercomprising introducing the selected fluid into the wellbore from asurface system.

Embodiment 14: The method according to any prior embodiment, whereinpositioning the pre-formed member includes arranging a woven material onthe outer surface of the tubular.

Embodiment 15: The method according to any prior embodiment, whereinpositioning the pre-formed me member includes securing a pre-fabricatedmat to the outer surface of the tubular.

Embodiment 16: The method according to any prior embodiment, whereinsecuring the pre-fabricated mat included adhesively bonding thepre-fabricated mat about the tubular.

Embodiment 17: The method according to any prior embodiment, whereinsecuring the pre-fabricated mat includes wrapping the pre-fabricated matabout the outer surface.

Embodiment 18: The method according to any prior embodiment, furthercomprising bonding a first end of the pre-fabricated mat to a second endof the pre-fabricated mat.

Embodiment 19: The method according to any prior embodiment, whereinpositioning the pre-formed member includes wrapping a continuous chordabout the outer surface.

Embodiment 20: The method according to any prior embodiment, whereinwrapping the continuous chord includes wrapping a first portion of thecontinuous chord having a first dimension and a second portion of thecontinuous chord having a second dimension that is distinct from thefirst dimension about the outer surface.

While one or more embodiments have been shown and described,modifications and substitutions may be made thereto without departingfrom the spirit and scope of the invention. Accordingly, it is to beunderstood that the present invention has been described by way ofillustrations and not limitation.

1. A tubular for reservoir fines control comprising: a body including anouter surface and an inner surface defining a flow path, a plurality ofopenings is formed in the body connecting the outer surface and the flowpath; and a pre-formed member including a material mesh overlaid ontothe outer surface, the material mesh being formed from a materialswellable upon exposure to a selected fluid introduced into a wellbore,the material mesh having a selected porosity allowing methane to passinto the flow path while preventing passage of fines.
 2. The tubularaccording to claim 1, wherein the selected fluid is introduced from asurface system into the wellbore.
 3. The tubular according to claim 1,wherein a portion of the material mesh extends at an angle relative to alongitudinal axis of the body.
 4. The tubular according to claim 1,wherein the pre-formed member comprises a pre-formed sleeve.
 5. Thetubular according to claim 1, wherein the pre-formed member comprises aweave.
 6. The tubular according to claim 1, wherein the pre-formedmember comprises a mat having a first end and a second end.
 7. Thetubular according to claim 6, wherein the mat is clamped to the outersurface.
 8. The tubular according to claim 6, wherein the mat is securedabout the outer surface with the first end being bonded to the secondend.
 9. The tubular according to claim 1, wherein the pre-formed membercomprises a continuous cord.
 10. The tubular according to claim 9,wherein the continuous cord includes a first portion having a firstdimension and a second portion having a second dimension that isdistinct from the first dimension.
 11. The tubular according to claim 1,wherein the pre-formed member is formed from a plurality of discreteparticles suspended in a binder material.
 12. A method of forming apermeable cover on a perforated tubular comprising: positioning apre-formed member including a material mesh permeable to a downhole gason an outer surface of the perforated tubular, the material mesh beingformed from a material swellable upon exposure to a selected fluidintroduced into the wellbore.
 13. The method of claim 12, furthercomprising introducing the selected fluid into the wellbore from asurface system.
 14. The method of claim 12, wherein positioning thepre-formed member includes arranging a woven material on the outersurface of the tubular.
 15. The method of claim 12, wherein positioningthe pre-formed me member includes securing a pre-fabricated mat to theouter surface of the tubular.
 16. The method of claim 17, whereinsecuring the pre-fabricated mat included adhesively bonding thepre-fabricated mat about the tubular.
 17. The method of claim 14,wherein securing the pre-fabricated mat includes wrapping thepre-fabricated mat about the outer surface.
 18. The method of claim 16,further comprising: bonding a first end of the pre-fabricated mat to asecond end of the pre-fabricated mat.
 19. The method of claim 12,wherein positioning the pre-formed member includes wrapping a continuouschord about the outer surface.
 20. The method of claim 19, whereinwrapping the continuous chord includes wrapping a first portion of thecontinuous chord having a first dimension and a second portion of thecontinuous chord having a second dimension that is distinct from thefirst dimension about the outer surface.